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ZIP KIT ®
PART NUMBER 6F35-ZIP QUICK GUIDE
Parts are labeled here in order of installation. See other side of sheet for details on kit contents.
1 6a Generation 2
Location
ONLY!
1
6a
Generation 1
1 Location ONLY! Solenoid
Valve Body
Main Control
Valve Body
Solenoid
Valve Body
Drill to .062" diameter. Insert
4 aluminum plug & peen in place
or insert optional rivet, snip
stem and peen in place.
In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum
testing and additional repair options for higher mileage units or for repairing specific complaints which are beyond the
scope of this kit.
Packaging Pocket 1 Remove and discard OE valve and spring. Keep outboard retainer clip
for reuse. Install Sonnax sleeve and valve as illustrated. Secure sleeve
• End Plugs (5)
in bore by installing included clip into sleeve groove at inboard port.
• O-Rings (7) 2 Extra Install included spring and secure all in bore with OE retainer.
Packaging Pocket 5
Generation 1
Valve Body Identification
Figure 1
9L8P
This ZIP Kit will service 6F35 Generation 1 (casting ID 9L) and Generation 2
(casting ID CV) applications (Figure 1). Detailed differences between the genera-
tions can be found in article "Solenoid Differences Between Ford 6F35 Gen. 1 &
Gen. 2 Transmission" on sonnax.com. However for the purposes of installing this
ZIP kit, the differences only affect the solenoid dampers. The location of the 1-2-3-
4 solenoid damper is the same for Gen. 1 and Gen 2. (Figure 2), but the damper
Generation 2 design is different. The Gen. 1 damper is shorter with a rubber tip, while the Gen. 2
CV6Z
damper is a longer piston with a spring. Gen. 2 has added 4 additional dampers to
the solenoid body - 3 long pistons with springs, and one short damper with a rubber
tip (Figure 10).
Technical Tips
Figure 2
Reprogramming
Many transmission performance complaints both prior to and after an overhaul
Piston can be addressed by reflashing the PCM or TCM. This includes any shift and/
or converter clutch scheduling issues, shift bumps, flares, bangs, etc. Refer to OE
reflashing procedure for further information.
NOTE: The TCM on the Ford 6F35 is not part of the valve body or transmission, but located
in the engine compartment.
Lead Frame
Identification: The original solenoid body Identification: The replacement solenoid body
tag on transmission case will look like this. tag on transmission case will look like this.
4th X X Overrunning
The solenoids are factory calibrated and vary in flow
5th X X Overrunning
rate. These solenoids can be replaced separately, but
6th X X Overrunning
*Turns off above 4mph.
only if the replacement solenoid has the same band
number as that which it is replacing (Figures 9 & 11).
Solenoid Apply Chart Figure 8 The band number is stamped on the solenoid can, and
SSA SSB SSC SSD SSE TCC is the last digit, which is either a 1, 2, 3, 4 or 5.
Gear (VFS) NL (VFS) NH (VFS) NL (VFS) NH (on/off) NC (VFS) NL
Generation 2 solenoids (Figures 10 & 13) do not have
Park X X
blue and yellow caps like Generation 1 (Figures 9 & 12).
Reverse X X
They instead have clear caps and brown/black snouts
Neutral X X
similar to the 6R80.
1st X X X
2nd X X X Figure 11
3rd X X X
Drive
4th X X*
5th X X* Solenoid
6th X X* Body ID
Number
KEY: X = On * = Modulating
Band
Number
No Screen Figure 10
6F35 Gen 1, Solenoid Band Number
Figure 13
EPC
SSC
SSB
SSD
6F35 Gen 2,
6F35 Generation 2 Solenoid Body Solenoid Band Number
2. Disassembly
a. To remove lead frame from valve body, remove
five small screws (green), (Figure 15).
CAUTION: Be careful not to bend or twist the OSS Lead Frame
lead frame or solenoid terminals during
removal, as damage can occur.
b. There are 14 solenoid retaining pins (two per Lead Frame Removal Figure 15
solenoid) that keep the solenoids in the casting.
Handle the casting with care so these do not fall
out and allow solenoids to come out and become 2
mixed up (Figure 16). 3
3. Installation
Install Zip Kit parts as shown on diagram of separate 5
quick guide sheet included in this Zip Kit. Sonnax
recommends vacuum testing critical wear areas not
covered by this kit to determine whether additional
Sonnax parts are required (see page 4 & 5).
2 Solenoid
Retaining
Pins
Note: Plug casting valley with foam, putty Clutch Select Valve
or appropriately sized O-ring coated in
assembly lube to isolate circuit. • Various shift concerns
• Shift codes
20
15
10
For specific vacuum test information, refer to individual part
25
30 0
5 instructions included in kits and available at www.sonnax.com.
VACUUM
TEST
OE Exploded View
Main Control Valve Body
NOTE: Depending upon vehicle application,
the OE springs shown may not be present. 101
110
1-2-3-4 Solenoid Damper
Gen. 1
109
Gen. 2
108 102
107
103
106
104
Pump Body
303
©2022 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company 6F35-ZIP_Booklet_E 07-28-22
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 7
FORD 6F35 (Gen. 1 & 2) ZIP KIT® Installation & Testing Booklet
OE Exploded View
Solenoid Valve Body
NOTE: Depending upon vehicle application, the OE springs shown may not be present.
203
SSD Solenoid
Damper,
Gen. 2 Only
SSB Solenoid
Damper,
Gen. 2 Only
202
SSC Solenoid
Damper,
Gen. 2 Only
Solenoid Valve Body Descriptions